Operator Quick Actions: Immediate Steps to Recover Availability

{ "Title": "Operator Quick Actions: Immediate Steps to Recover Availability", "IntroductionHtml": "

Purpose: Use this quick checklist during the first 10 minutes of any unplanned stop to keep people safe, stabilize the situation, capture consistent data, and either restart the line or escalate clearly.

Keep responses brief. If you need to escalate, notify the right role immediately after completing the safety checks. This form saves a standardized record for later root-cause work.

", "SubmitLabel": "Save Triage Record", "SuccessMessage": "Triage record saved. If you escalated, expect the notified team to respond. Complete any required follow-up or open a deeper investigation ticket if needed.", "DataType": "operator-triage-record", "SchemaVersion": "1.0", "Fields": [ { "Key": "stop_time", "Type": "text", "Label": "Stop time (HH:MM)", "HelpText": "Enter the time the machine stopped. Use 24-hour format if standard in your plant.", "Required": true }, { "Key": "operator_name", "Type": "text", "Label": "Operator name / ID", "HelpText": "Who is completing this triage?", "Required": true }, { "Key": "safety_checks_done", "Type": "checkbox", "Label": "Safety & LOTO reminders (check all done)", "HelpText": "Complete these before any hands-on troubleshooting.", "Options": [ { "Value": "loto_verified", "Label": "LOTO verified where required" }, { "Value": "area_cleared", "Label": "Area cleared of non-essential personnel" }, { "Value": "ppe_confirmed", "Label": "Required PPE confirmed" }, { "Value": "energy_isolated", "Label": "All energy sources isolated/secured" }, { "Value": "guards_in_place", "Label": "Guards and barriers returned where needed" }, { "Value": "other", "Label": "Other (specify below)" } ] }, { "Key": "safety_other", "Type": "text", "Label": "If other, describe:", "HelpText": "Only use if you checked 'Other' above." }, { "Key": "is_restartable", "Type": "yesno", "Label": "Is the machine restartable right now?", "HelpText": "Can you safely attempt a restart after immediate checks and containment?", "Required": true }, { "Key": "temporary_workaround", "Type": "yesno", "Label": "Was a temporary workaround implemented to resume production?", "HelpText": "A workaround could be a temporary fix, part substitution, or operating change to keep product moving.", "Required": true }, { "Key": "workaround_description", "Type": "textarea", "Label": "If yes, describe workaround (brief):", "HelpText": "What was changed, who approved it, and how long is it acceptable?" }, { "Key": "suspected_cause", "Type": "select", "Label": "Suspected cause (select best match)", "HelpText": "Choose the most likely cause based on what you observed. This helps triage and later RCA.", "Options": [ { "Value": "mechanical", "Label": "Mechanical component/failure" }, { "Value": "electrical", "Label": "Electrical/fuse/motor" }, { "Value": "tooling", "Label": "Tooling/fixture problem" }, { "Value": "material", "Label": "Material/part supply" }, { "Value": "process", "Label": "Process parameter/out of spec" }, { "Value": "operator_error", "Label": "Human/operator error" }, { "Value": "upstream_supply", "Label": "Upstream supply or feeder" }, { "Value": "control_software", "Label": "Control/PLC/software" }, { "Value": "utility", "Label": "Utility (air, water, power)" }, { "Value": "other", "Label": "Other (specify)" } ], "Required": true }, { "Key": "suspected_cause_other", "Type": "text", "Label": "If Other, describe suspected cause:", "HelpText": "Brief note for the record." }, { "Key": "immediate_actions", "Type": "textarea", "Label": "Immediate containment & actions taken (brief, bullet style)", "HelpText": "e.g., isolated zone, swapped spare part, restarted feeder, logged serial #. Keep to the facts." }, { "Key": "time_to_restart_minutes", "Type": "number", "Label": "Minutes from stop to restart", "HelpText": "Enter minutes. If not restarted, enter -1. This helps track MTTR." }, { "Key": "quick_test_performed", "Type": "yesno", "Label": "Quick 5-minute test performed to validate restart stability?", "HelpText": "A short run to confirm restart is stable before returning to normal production." }, { "Key": "quick_test_result", "Type": "radio", "Label": "Result of the quick test", "Options": [ { "Value": "stable", "Label": "Stable — no recurring faults" }, { "Value": "intermittent", "Label": "Intermittent issues observed" }, { "Value": "failed", "Label": "Failed — stop recurred" }, { "Value": "not_applicable", "Label": "Not applicable / not performed" } ] }, { "Key": "containment_notify", "Type": "checkbox", "Label": "Who was notified during triage? (check all)", "Options": [ { "Value": "supervisor", "Label": "Supervisor / Shift Lead" }, { "Value": "maintenance", "Label": "Maintenance" }, { "Value": "safety", "Label": "Safety" }, { "Value": "quality", "Label": "Quality" }, { "Value": "production_planner", "Label": "Production Planner / Scheduler" }, { "Value": "engineering", "Label": "Engineering" }, { "Value": "other", "Label": "Other (specify)" } ] }, { "Key": "containment_notify_other", "Type": "text", "Label": "If Other, specify who was notified:", "HelpText": "Name or role." }, { "Key": "escalation_required", "Type": "yesno", "Label": "Is escalation required beyond normal shift support?", "HelpText": "Escalate when safety is at risk, restart not possible, or repeat/unresolved faults occur.", "Required": true }, { "Key": "escalate_to", "Type": "select", "Label": "If yes, escalate to:", "Options": [ { "Value": "maintenance_team", "Label": "Maintenance Team" }, { "Value": "engineering", "Label": "Engineering" }, { "Value": "plant_manager", "Label": "Plant Manager / Duty Manager" }, { "Value": "safety", "Label": "Safety" }, { "Value": "quality", "Label": "Quality" }, { "Value": "other", "Label": "Other (specify)" } ] }, { "Key": "action_owner", "Type": "text", "Label": "Action owner (who will follow up / repair)", "HelpText": "Name or role responsible for next steps.", "Required": true }, { "Key": "follow_up_required", "Type": "yesno", "Label": "Is follow-up or formal RCA required?", "HelpText": "Select 'Yes' if a problem needs deeper investigation to prevent recurrence." }, { "Key": "follow_up_notes", "Type": "textarea", "Label": "If follow-up required, short notes on next steps:", "HelpText": "What should be investigated, who should own it, and any immediate evidence to keep." }, { "Key": "root_cause_ticket", "Type": "text", "Label": "Root-cause / work order / ticket number (if created)", "HelpText": "Enter the reference if your team already opened a formal ticket." }, { "Key": "evidence_ref", "Type": "text", "Label": "Photo / evidence reference", "HelpText": "Enter filename, tag, or location where any photo or video is stored. (Use standard site method.)" }, { "Key": "confirm_accuracy", "Type": "yesno", "Label": "I confirm the above entries are accurate to the best of my knowledge", "Required": true } ] }